Brazilian Pipeline Community

The Brazilian Pipeline Community
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The Brazilian Pipeline

Contents
Liquid Pipelines and Terminals
Joo Carlos de Luca President, IBP
The Brazilian Institute of Petroleum and Gas (IBP) with the support of its Pipeline Commission has been working to develop Brazils pipeline industry by helping companies in this sector operate in a profitable, efficient, ethical and socially responsible way. In this context, the Commission promotes the exchange of ideas and experience amongst professionals in this industry and is active in the areas of norms standardization, promoting international trade missions and in the organization of courses and events. Among the latter we can highlight the Rio Pipeline Conference and Exhibition as a world class forum to debate the major issues facing the international pipeline industry.
Marcelino Guedes Director, Petrobras Transporte
a free standing hybrid riser for deepwater

Francisco E. Roveri Petrobras R&D CENPES
Projects and Construction of New Oil and Gas Pipelines in Brazil Pipeline Integrity Program
Breno de Souza e Silva & Ney Passos Petrobras Engineering
Paulo de Tarso Arruda Correia Petrobras Transporte
Brazils Pipeline Technology Center CTDUT

Raimar Van den Bylaardt CTDUT
Social and Environmental RESPONSIBILITY

Ana Paula Grether de Mello Carvalho
Submarine Pipeline Inspection

Claudio Camerini & Miguel Freitas
Pipeline and Shipping Technology supports Petrobras
Csar Jos Moraes Del Vecchio, Petrobras R&D CENPES
the Brazilian Gas Transportation System

Marcelo Renno Director, Petrobras Transporte
Route Selection and Structural Design for the Golfinho Gas Export Pipeline
Marcelo Jos Barbosa Teixeira, Claudio Roberto Mansur Barros, Mnica de Castro Genaio, Carlos Terencio Pires Bomfimsilva, Vivianne Cardoso Pessoa Guedes, Janaina de Figueiredo Loureiro Wajid Rasheed CEO & Founder, EPRasheed
Brazil has the potential to export world class technology and services. For this to happen, an export culture needs to be cultivated. Part of this culture is a single source of technical material that focuses on Brazil while including the wider international observers. This supplement The Brazilian Pipeline Community is a channel for companies, both oil and service to share expertise with the wider export market.
Editors
Andre Raposo, Daniel Brossi, Breno Souza, Ney Passos, Francisco Roveri, Pedro Barusco, Paulo Correia, Ana Paula Carvalho, Marcelo Renno, Marcelo Teixeira, Claudio Barros, Monica Genaio, Carlos Pires, Vivianne Guedes, Janaina Loureiro. Contact: andreraposo@petrobras.com.br
Publisher
Wajid Rasheed wajid.rasheed@eprasheed.com
Managing Editor
Majid Rasheed majid.rasheed@eprasheed.com
Brazil oil & Brazil gas oil & gas

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Community Viewpoints
Sergio Gabrielli President, Petrobras Ildo Sauer Director, Petrobras Gas and Power Area
Petrobras is changing from an oil company into an integrated energy Company. Natural gas is playing a fundamental role in the organization as its share of the Brazilian energy matrix increases. As a result, the investments allocated for the natural gas chain in the 2007-2011 period amount to US$22.1 billion, a 71 percent increase over the previous budget.
Paulo Roberto Costa Director Petrobras Bunkering

Strategically important to supply energy to Brazil, Petrobras pipeline network operates in strict accordance with Health, Safety and Environmental standards. Through advanced monitoring technology, we can guarantee the safe transportation of raw materials and products at competitive costs.
Over the next few years we will be witnessing the third boom in pipeline activity in Brazil. Building new oil, natural gas and bio-fuel pipelines will be our challenge. We will look to new technologies to ensure environmental and operational safety with social responsibility.
Sergio Machado President, Petrobras Transporte
Eloi Fernandez y Fernandez Director General, ONIP (The National Petroleum Industry Organisation)
Since 1999, ONIP has been working to increase local content in oil and gas projects in Brazil. For the pipeline sector, we have recently released a publication, entitled Who is Who in the Pipeline Industry in Brazil. Our main objective here, is to present local capacity to investors, as we are very optimistic about the future of the Brazilian pipeline industry.
Renato Duque Director Petrobras Services
Transpetro has prepared itself to meet increasing demand generated by self-sufficiency and the growth of Brazils oil and gas sector. New ships, terminals and pipelines will guarantee logistical supply in a country that has the dimensions of a continent. Acquired over the last 30 years, our experience of Ethanol logistics places our company as the industry benchmark and market leader.
Raising professional skills and implementing new pipeline construction and monitoring technologies are our challenges. Our goal is to expand the pipeline network in a safe and efficient manner while minimising environmental impact.
Liquid Pipelines and Terminals

Marcelino Guedes, Director - Petrobras Transporte
Transpetro is present in the whole of Brazil, through the operation of 44 terminals and a pipeline network of around 7,000 km of oil pipelines, operating from the north of the country in the Amazon region pipelines ORSOL I and II and terminals in Coari, Manaus and Belm to the extreme south Rio Grande Terminal. With an infrastructure of around 500 stor-
age tanks for oil and oil products, in addition to 80 globes for LPG, Transpetro has the installed capacity to store approximately 10 million m and transport around 53 million m/month of oil and oil products, in addition to handling around 4,600 shipping operations per year. Complementing the infrastructure of these terminals, Transpetro owns two multiple
buoy mooring systems and five mono-buoys, with the objective of unloading in locations where the coastal conditions do not allow the mooring of ships.
Operational Safety
Transpetro maintains the consistent policy of improving the safety of its operations. In the Pipeline Integrity
Liquid Pipelines and Terminals Guedes

Program (PIP) alone, US$ 630 million have been invested with the result being a reduction in the volume of leaks to the order of 93%. PIP, which is destined to ensure perfect functioning of the installations and reliability of operations, has been continuously revised and has gained new monitoring tools. The implementation of the Terminal Integrity Program (TIP) began in 2005. This will establish a series of technical projects with the objective of achieving excellence in the safety and integrity of the installations and infrastructure of the units. The integrity programs for pipelines (PIP) and terminals (PIT), which include stabilization of the slopes, renovation of piers and storage tanks are being enhanced by the training of the workforce. The National Operational Control Center (NOCC) ensures the standard of safety for the operational control of the pipeline network throughout Brazil. From there, the technicians accompany remotely and in real time the operations in the pipelines. NOCC is equipped with computers and the leading edge technology. Supported by the Supervisory Control and Data Acquisition (SCADA) software, the operators receive immediate detailed information about what is happening in the pipelines and monitor the levels of flow, pressure, temperature and density of the oil and the gas. At the least sign of any abnormality, the system allows for telecommand interventions such as the switching on or off of pumps, or the opening or closing of valves in any stretch. Pipelines and terminals, just like all of the Transpetro installations, comply with norms that go beyond the regulatory demands, having the voluntary certifications for the Integrated Management of Quality, Health, Safety and the Environment (QSMS) ISO 9001 (quality), ISO 14001 (environment) and OHSAS 18001 (international norm for occupational safety) being evaluated by international certifying agencies. Within the projects aimed at increasing operational safety pipelines, is the Program for the Greater So Paulo Outflow Logistics Reformulation. The project, with investment of around US$1 billion, substitutes the existing pipeline network installed in the metropolitan region of So Paulo, with an external network. The objectives are to provide the network with the capacity to handle growing volumes of oil, oilderivatives and other products. And to reduce the safety risks associated with heavy urbanisation along pipeline rights-of-way in Greater So Paulo. In addition to all the care taken with operational safety, Transpetro maintains an infrastructure to respond to emergencies that includes a Center for Emergency Pipeline Repairs (CREDUTO) in Guarulhos So Paulo, and 49 Emergency Response Centers (CREs and CDAs) spread around the country, with equipment and teams trained for a rapid response to any accident with a possible impact on the environment.
Graphic shows Petrobras Emergency Bases
New Projects
The increase in the price of oil and the growth in demand for fuels with less impact on global warming have led to the search for biofuels. In Brazil, the Transpetro Program for Ethanol Logistics gained impetus due to the Brazilian experience with alcohol technology, and the prediction that by 2014 demand for
CREs Transpetro Management 34 CDAs Petrobras Management 9 Advanced CDA Bases 6

ethanol will reach 25 million m in the domestic market and 5.5 million m abroad. Transpetro is preparing to increase its capacity of fuel ethanol outflow from the present 1.2 million m per year to 9.4 million m per year in 2015, with investments in exclusive pipelines and tankage in the Southeast, the South and the Northeast of Brazil amounting to US$532 million. The principal investments are as follows: Ethanol pipeline Paulnia-Guararema: exclusive pipeline for ethanol with the capacity for eight million m per year with an investment of US$ 154 million. Ethanol pipeline Uberaba-Ribei ro Preto-Paulnia: capacity to transport four million m per yearwith an investment of US$100 million. Tiet-Paran Waterway: capacity for transporting four million m of ethanol per year from the west of So Paulo, Mato Grosso and Gois to Paulnia and take the same quantity of diesel oil and gasoline from Paulnia back to these regions. The investment is US$ 236 million. Ethanol pipeline Guararema-So Sebastio: capacity for four million m per year. The investment is still being evaluated. Construction of three more tanks at the Macei Terminal, increasing the capacity from 400,000 m per year to 700,000 m per year. The investment is US$ 4 million. Paranagu Terminal: adaptation of an existing tank, construction of two additional tanks and a platform for tanker trucks with the enlargement of the wagon platform to increase the capacity from 400,000 m per year to 700,000 m per year. The investment is US$ 4 million. The highlight among the new projects for oil pipelines is the study for the implantation of a pipeline of around 1,400 km between the REPAR Refinery in Araucria and the cities of Londrina, Campo Grande and Cuiab, with the objective of reducing the logistics cost of transporting oil products to the central-west region, meeting the growing demand generated by the expansion of agribusiness in that area. The increasing demand for natural gas in Brazil, predicted to grow by 14% per year to 2010, accompanied by the need for diversifying supply, has led to the acceleration of projects for water-based terminals with the capacity to receive, vaporize and dispatch natural gas. For this purpose, projects are being developed for the implantation of terminals capable of receiving ships carrying Liquefied Natural Gas (LNG) initially in Ilha Dgua Rio de Janeiro, in the southeast of Brazil and in PECEM Cear, in the Northeast.
Graphic shows Schematic of Pipelines
New riser development a free standing hybrid riser for deepwater

Francisco E. Roveri Petrobras Research & Development Center CENPES/Subsea Technology Group
Introduction
Petrobras is considering the singleline FSHR (Free Standing Hybrid Riser) design as an option for large diameter export risers in deepwater. This large bore specification combined with the deepwater environment put this application outside the present feasibility range of solutions such as flexible pipes and steel catenary risers (SCRs). Both these solutions present high top tension loads for installation and operation. The lateral buckling failure mode in flexible pipes and the fatigue damage in the touch down zone (TDZ) of SCRs are further design limitations currently only solved by the use of heavier pipes which further compromise hangoff loads in a negative design spiral. The FSHR system has a reduced dynamic response, as a result of significant motion decoupling between the Floating Production Unit (FPU) and the vertical portion of the FSHR system and its vessel interface loads are small when compared with SCRs or flexible pipe solutions. Therefore it is an attractive alternative solution for this kind of application. There are further cost savings associated with this concept due to the added advantage of having the riser in place prior to the installation of the FPU.
The hybrid riser concept, which combines rigid (steel) pipes with flexible pipes has been utilized by the offshore industry since the 80s. The Riser Tower first installed by Placid Oil at Gulf of Mexico in Green Canyon 29 was refurbished and re-utilized by Enserch. More recently, the concept underwent some changes for application at Girassol field in Angola, where three towers were installed by Total. The Riser Towers at Girassol field are positioned with an offset with regard to the FPU, whereas at GC29 the vertical portion of the riser was installed by the semi-submersible FPU and was located underneath the derrick. Five water and gas injection monobore FSHRs (10 to 12-inch) have recently been installed in West Africa offshore Angola, at Kizomba field in about 1200 meters water depth. The design of these risers has some key differences to one of the concepts presented in this paper, each of which offers different design and operational advantages. Riser towers are being developed for installation in the Greater Plutonio and Rosa fields in Angola. Petrobras has been studying the hybrid riser concept for some years. In 1989 a feasibility study was developed for Marlim field, Campos Basin, for a configuration similar to the one uti-
lized by Placid. After a long period, it was only in the year 2000 that this alternative was considered for conceptual studies at Albacora Leste field, in 1290 meters water depth, for the P50 turret moored FPSO. Two alternatives were considered for comparison: a Steel Lazy Wave Riser (SLWR) and a concept combining rigid and flexible pipes. In 2003 Petrobras contracted the conceptual study development of the Riser Tower solution for the starboard side 8-inch production lines of the P52 semi-submersible platform. Two towers were considered, each comprising seven production lines and one spare line. In 2003 Petrobras also contracted the feasibility studies of an export oil FSHR to be connected to a semi-submersible platform in water depths of 1250 and 1800 meters.

System Description
The FSHR design may have a number of variants. Two configurations are presented hereinafter, the main difference being the interface between the Buoyancy Can (BC), the vertical pipe and the flexible jumper. The FSHR runs from the hangoff slot at FPU to the Pipeline End Termination (PLET) located near the riser base. The lower end of the vertical part interfaces with a stress joint. Below the stress joint there is the offtake spool, which connects to the foundation by means of a hydraulic connector. A rigid base jumper connects the mandrels located at the offtake spool and PLET, providing the link between the FSHR and the pipeline. The foundation pile will be drilled and grouted and may typically be offset from the FPU by more than 200 meters. The riser pipe passes through an inner 36-inch OD stem within the BC, and is guided within the stem by centralizers. Where the riser pipe is subject to high bending loads such as the keel ball centralizer on the BC, taper joints are used to reduce the stress in the riser pipe. The BC is secured to the riser pipe at the top of the BC by means of a bolted connection. At the top of the free-standing riser is the gooseneck assembly. This assembly consists primarily of the gooseneck and an ROV actuated hydraulic connector which allows the gooseneck and flexible jumper to be installed separately from the vertical section of the riser. Attached to the gooseneck is the flexible jumper. The flexible jumper connects the freestanding section of the riser system to the vessel, and includes bend stiffeners to ensure that the range of rotations experienced at the end connections do not damage the jumper due to low radius of curvature. The flexible jumper has enough compliance such that the vessel motions and offsets are substantially decoupled from the vertical portion of the FSHR system, and consequently the wave-induced dynamic response of the free standing riser is low.
Configuration A
The configuration described below is considered for an oil export riser to be installed from a MODU (Mobile Offshore Drilling Unit), due to the availability of such vessels already under contract at Campos Basin. The FSHR consists of a single near vertical steel pipe connected to a foundation system at the mud line region. The standard riser joints are 18-inch OD x 5/8-inch wall thickness X65 material. The riser is tensioned by means of a BC, which is mechanically connected to the top of the vertical pipe. The vertical pipe is always kept in tension in order to maintain the FSHR stable for all the load cases. The BC is 36.5 m long x 5.5 m diameter. It has 16 compartments and the maximum upthrust is about 570 Te. The BC is located 175 meters below the sea level, therefore beyond the zone of influence of wave and high current.
Configuration B
The position of the gooseneck in relation to the BC is the main difference between the West African and Configuration A designs. In the earlier design, the gooseneck is positioned below the BC and the vertical riser is tensioned by the can via a flexible linkage or chain. This arrangement simplifies the interface between the BC and vertical riser, and allows pre-assembly of the flexible jumper to the gooseneck before deployment of the vertical riser. However, in the event of flexible jumper replacement or repair, an elaborate jumper disconnection system needs to be employed below the BC.
Fig. 1 shows Configuration A.
Fig. 2 presents Configuration B.
Riser Development Roveri

Positioning the gooseneck at the top of the BC allows for independent installation of vertical riser and flexible jumper. A flexible pipe installation vessel can install the flexible jumper when required. This minimizes the risk of damage to the flexible jumper during installation as the procedure is similar to that of a shallow water flexible riser with the first end at the top of the BC. This design also facilitates and minimizes the time for flexible jumper retrieval in case of damage, in service, to any of its components such as the stiffener, end-fittings or pipe outer sheath. On the other hand, it is necessary to have a continual vertical riser string right through the centre of the BC to provide a connection hub for the flexible jumper at the top. This arrangement introduces interfaces between the riser string and BC which have to be carefully analyzed and engineered. In addition, installation analysis has to be conducted to assess the loads on the riser string during deployment through the BC. Other differences are the foundation type (suction piles x drilled and grouted pile) and bottom interface (flexjoint x tapered stress joint). Configuration B presents the gooseneck positioned below the BC. The vertical riser is tensioned by the BC via a flexible linkage or chain and the hub is in offset with regard to the vertical section of the FSHR. This allows the flexible jumper to be installed in a similar way as Configuration A, therefore overcoming some disadvantages of this configuration and previous designs. suited to deepwater applications. The design is relatively unaffected by severe environmental loading or non-heave optimized host vessels when compared to SCRs and flexible risers. The robustness allows the riser to be conservatively analyzed, and allowances for design changes and uncertainties to be included upfront in the design process, thus giving greater confidence in the overall system design. For engineering, procurement and construction (EPC) contractors not having a suitable vessel, or unable to mobilize their vessels to install the FSHR, the ability to use a MODU as the installation vessel could prove to be an attractive alternative. It can be said that the FSHR concept extends the reach of deepwater riser feasibility as it avoids the main technical problems faced by other solutions, and arguably, it may be among the few proven riser concepts feasible for deepwater large bore applications.
Conclusions
In the FSHR design concept, the location of the BC below high current and wave zone, and the use of the flexible jumper to significantly decouple vessel motions from the vertical riser greatly reduce the system dynamic response, resulting in a robust riser design particularly
Always innovating for the best
Azevedo & Travassos develops innovative solutions to meet the needs of its Oil and Gas clients. Consequently, it is recognized as one of Brazils Foremost Construction Companies with the best know-how in the market. The result of this investment can be described by a single word: credibility. In the end, those that have been working for so long, can only do things well.
Projects and Construction of New Oil and Gas Pipelines in Brazil

Breno de Souza e Silva & Ney Passos Petrobras Engineering
General Considerations
In light of ever-growing gas demand and the increasing difficulty of meeting such demand through gas importation, Petrobras envisaged Brazilian self-sufficiency in natural gas production and is accelerating the process of achieving it. Today, the consumption of the country is 45.5 million cubic meters per day and by the year 2011, it may reach 121 mil-
lion cubic meters per day, of which 71 million will be produced in domestic fields. Additionally, the demand for transportation of crude oil and derivatives is also growing. The installation of new refining units and the revamping of some existing ones were required to meet a growing market, which ranges from fuel consumption to petrochemicals. The Brazil-
ian consumption of oil derivatives in 2005 was 1.766 thousand bpd, with an estimated growth of 3.1% p.a in the next five years, reaching a expected consumption of 2,117 thousand bpd in 2011. Such is the background to the investment plan of the oil and gas pipeline network expansion in the country, bringing about new jobs as well as new technologies. In or-
Souza & Passos

der to meet the demands of the gas market and make it possible for field production flow, Petrobras is investing US$ 4.4 billion in the next five years in the enlargement of the gas pipeline network. With respect to the increase in oil pipelines and terminals, the expected investment for the next five years is US$ 3.0 billion. aged which will either be rented or owned by Petrobras. This will result in roughly 30 turbo-compressor sets with installed power varying from 7.200 HP to 23.800 HP each. Petrobras is also investing in the development and improvement of the operating and safety conditions of terminals and pipelines, many of which are in urban areas. To this effect, the So Paulo Master Pipeline Plan (PDD-SP), foresees transportation of oil, derivatives, natural gas and alcohol through a new pipeline and right-of-way network introducing optimized operating logistics and substituting the existing network, which will interconnect terminals and distribution companies in the state of So Paulo. The purpose of such modifications are the adaptation of paths and strips of land along the pipelines route so that they blend in better with the surrounding communities, as well as preparing the network to cope with the growth of the state of So Paulo. The petrochemical complex of Rio de Janeiro (COMPERJ) will also require the construction of new pipelines, including crude oil and petrochemical. It is worth noting that Petrobras faces considerable challenges with regard to the construction of oil and gas pipelines. There is an extensive oil and gas pipeline that needs to be implemented and operated in a safe and socially responsible way. And time runs short as the number of projects increase. To rise to such challenges Petrobras is counting on technological innovations, which are under development. Society is also called to provide the necessary resources as qualified manpower and a competitive and efficient industry to supply equipment and material of proven quality. It is worth mentioning the national oil and gas industry mobilization program (PROMINP) developed by the federal government. The issues related to health, safety and environment cannot be forgotten. The works to be implemented require social responsibility and maximum care and respect to the particular characteristics of the regions crossed by the pipelines. To provide efficient outflow of large volumes, pipelines with greater diameters and higher pressure ratings are required. Increasing steel resistance means avoiding greater thickness of pipe. The benefits include saving steel by weight reduction, and therefore, the costs of pipe purchasing, pipe construction and assembly are all reduced. At present, the oil and gas pipelines of greatest resistance in Brazil are manufactured with pipes of X70 degree in conformity with API 5L specification, which has reliable construction and assembly techniques. On the other hand, Petrobras has participated in many attempts to innovate pipe fabrication technology, such as the study of fabrication and application of API 5L X80 pipes, the evaluation of new welding processes for highly resistant steels, the study for application of pipes with helicoidal welding, as well as its participation in the working out of the Brazilian standard for heat bending by induction.
Pipeline Projects
Regarding projects and construction of oil and gas pipelines, the actions taken by the Engineering department of Petrobras have already shown practical and visible results. In the Northeast region of the country we find unmet gas demand, which has resulted in increased investments in the transportation and distribution infrastructure, mostly based on thermoelectric plants for power generation. The Southeast region already has a booming transportation and distribution network, especially in Rio de Janeiro and So Paulo, where gas consumption is high. The projects to expand pipeline network are also encouraged by the growth of the piped gas distribution network in the metropolitan regions as well as the demand related to industry and thermoelectric plants. If we only consider existing oil and gas pipelines we may note that our gas pipeline system in Brazil is not wholly integrated. However, the unmet demand from the Northeast, the first production from fields in the Esprito Santo and the promising Southeastern market will be interconnected by the GASENE Gas Pipeline. For these gas pipeline networks, 10 compression stations are envis-
Conclusion
The expansion of Brazils oil and gas pipeline network is a fundamental necessity in order for the economic growth of our country. The Engineering Department of Petrobras is fully committed to this goal and is not sparing any efforts in order to develop the new technology required to complete new projects.
Transpetro Pipeline Integrity Program

Paulo de Tarso Arruda Correia, Petrobras Transporte S. A. Transpetro
Introduction
The project is part of the PEGASO Program (Operational Safety and Excellence in Environmental Management). It started in 2001, with a large and intense pipeline physical integrity recovery program, followed by the adjustment of the companys pipeline grid (more than 9,650 km of natural gas, oil and oil product pipelines) and led to the new Petrobras Integrity Standard or PID (Padro de Integridade de Dutos). The Program was started after three pipeline accidents in the country; the first one in Guanabara Bay with a fuel oil line (PEII 16, 13.7 km) in January/2000, resulting in a leakage of 1300 m3; the second in a crude pipeline in July/2000 (OSPAR 30, 118.5 km) with 4000 m3, lost and the third one in a diesel pipeline (OLAPA 12, 94.0 km) with 150 m3 lost in 2001. A fourth accident with a fuel oil pipeline (OBATI 14, 50 km) happened in May/2001 due to external corrosion resulting in a leakage of 200 m3 of atmospheric residue, and a fifth in July/2001 in OBATI Clean products 14 pipeline due to Third Party Action also resulting in a leakage of 200 m3 of LPG. Transpetro has invested more than US$600 million to date, aiming to adjust its pipeline network to the new level of integrity demanded by PID.
This new standard began establishing routines for inspection, control and mitigation for what were called four main failure modes: Internal Corrosion; External Corrosion, Third Party Action; Pipe and Soil interaction. The PID document comprised eight chapters covering: Risk Analysis; Internal Corrosion; External Corrosion; Third Party Actions; Soil and Pipe Interaction (Geotechnical Problems); Pigging; Defect and Repair Analyses; Pressure Testing. All these PID chapters were applied to each pipeline in the companys network in a way that the control of the program was carried out per pipeline. Standard as a permanent practice of the company.
The Emergency Phase

This was applied to a priority list of 96 pipelines (6,084.9 km) selected for strategic and risk reasons. These were selected from among the 183 pipelines (9,650 Km) that would be considered in the whole program. In this emergency phase, more than 245 km of new and different pipelines, representative of the installed base considering items such as nominal diameters, material and wall thicknesses, were purchased and used to assist in the repairs that came after an in-line inspection program, using MFL or ultrasonic pigs. A total of 5,480.1 km of pipeline was inspected through intelligent pigs (geometric, high resolution
Program Structure
The program as a whole, delivered a reduction in the leakage volume from 6,000 m3 in 2000, to less than 39 m3 in 2003, the leakage has been kept at a very low level since then. Three phases and five processes were identified. These were the Emergency Phase to rapidly recover the physical integrity of a set of prioritised pipelines. This included the assessment and recovery of integrity as well as adjusting the whole pipeline network to the Petrobras Pipeline Standard. Additionally, it included the introduction of the Pipeline
Transpetro Pipeline Integrity Program

After a careful experimental research program, Petrobras developed a selfintegrity criterion for the assessment of pipelines with corrosion defects. The RPA methodology may be used alternatively for ASME B31-G, generating a reduction of 49% in the preventive repairs carried out after in-line inspections. Petrobras also has a laboratory devoted to the development and tests of smart-pig tools in its Research Center, CENPES. This laboratory has developed tools of different types such as Geometric, MFL, pressure and temperature profiler with an accelerometer and new technology for internal corrosion and geometry deploying the polygraph principles. The following areas have been researched:
Transpetro's Pipeline Network Regional NNE SE SPCO SOUTH TOTAL 42 60 61 20 183
Quantity Nr. Pipelines Nr. Row 15 14 27 9 65
Lenth KM 2596,83 2763,54 3260,00 1029,90 9650,28
MFL and ultrasonic) resulting in the repair of 5,200 defects. This resulted in 5,094.3 km of rehabilitated pipeline. During this phase more than 87 new employees were hired to work in the integrity area and almost US$400.00 million were invested. This phase started in early 2001 and ended in 2003 (the target was 07/2002 but the repairs continued until mid 2003).
problems, etc. The headquarter's committee performs the whole program coordination, issuing a monthly report and keeping a specific site on the company home page. Transpetro has created a standard, negotiated with the ILI services provider companies, for the format of pig inspection reports (magnetic and hard copy) that make the interpretation easier as well as the data processing, using a toll that estimates the wall resistance, the defects that must be repaired as well as defining the next inspection (described below) called Planpig. Planpig is a novel methodology developed by Transpetro for pipeline management in-line inspection programs. This software was developed to determine the best (risk and cost based) time interval between in-line inspections and the preventive repairs to be carried out following a pipeline inspection. The innovative feature of this methodology is that it takes into account the expected failure cost, the cost of inspection and the cost of repair to determine the optimal failure risk at the moment of inspection as well as the ILI tool accuracies and internal and external corrosion rates. By applying this methodology a reduction of 46% in the expenditure on in-line pipeline inspection was obtained.
The Adjustment to Petrobras Pipeline Standard

In this phase all Pipeline standardization actions were applied to each pipeline through a variety of different projects and according to a WBS (Work Breakdown Structure). The management of the program considered a structure composed of five Committees, one in headquarters and one in each of Transpetros regions. Typically, the Regional Committees brought together representatives of the following areas: Health, Safety and the Environment; Commercial; Marine Terminals; Oil Pipelines; Gas Pipelines; Engineering. The Regional Committee promoted periodic coordination meetings where the different agents had the opportunity to exchange ideas, update each other regarding the progress in their activities, discuss
Internal Corrosion (IC)

In order to control and mitigate the IC, the project in this area comprised the following main items: Implantation of infra-structure including: Petrobras project and installation of corrosion coupon and Electrical Resistance Corrosion Probes (ERCP) in the 6o/c position (bottom line of the pipes). Development of new corrosion inhibitor additives, injection stations and updating the existing units with automation. Implementation of a set of routine services considering: Periodical cleaning of the pipelines with scraper pigs: IC management service routine to collect samples from the debris dragged by the scraper pigs, NACE test of samples from product batches pumped through the pipelines.

External Corrosion (EC)
In EC the project encompassed the following items: External coating survey using PCM, ACVG, DCVG and CIPS for mapping and sizing the discontinuities in the external coating as well as being a way to provide the mapping of the pipelines at the ROW (Right Of Way) without the mapping tool. ic map, and takes into account the results of special and periodic surveys. Among the most common problems are: River crossing erosion causing the pipeline exposition leading segments to be without support; Soil movement in mountain slopes (hillsides); Soil erosion with the exposition of the pipeline by heavy rain; The collapse of the soil by underground water movement; The actions of strong waves or strong tides in the sea to beach transition. than 5 years, and that need to operate again; Pipelines that have been operating at one pressure level that need to operate at a pressure 25% higher, although lower or equal to the one allowed by the last test. Pipelines that have been operating for more than 25 years without a new valid pressure test; Pipelines out of operation, even in periods lower than 5 years that have not had an appropriate hibernating process. These criteria were applied to the pipeline network, and as a result, 101 pipelines were tested.
The CPS Supervisory System

A great advance in the program was the application of the supervisory system for the CPS. This system called STR (Sistema de Telesuperviso Remota) is based on a set of sensors installed in the rectifiers or the interference current drainage equipment like voltmeters (AC and DC), current meters (DC output current), soil to pipe voltmeter with a permanent semi-cell and a switch in the entrance door to detect invaders in the rectifier shelter.
Risk Analyses
The Risk Analyses chapter in the Petrobras Pipeline Standard is one of the most important in the whole document. It is the qualitative analyses that consider the consequence potential and the failure probability of the four failure modes considered in the PID. The pipelines are divided into segments according to the geographical and environmental factors. The consequence potential takes into account: the environmental classification; class location; operational conditions like product, flow rate and pressure (only for natural gas pipelines). All 183 pipelines in the network had their risk evaluated by this process.
R&D in Pipeline, Pipeline Technological Center, Cooperative Projects

Petrobras has in its Research and Development Center (CENPES) a laboratory devoted to the development and testing of smart pigs tools. This laboratory has developed Geometric tools, MFL and pressure/temperature profiler. Recently, Transpetro took part together with other companies in the foundation of an independent and private Pipeline Technological Center (CTDUT Centro Tecnolgico de Dutos). Two pipeline loops are being constructed, the larger one with 12, 2.4 km for liquids and the smaller one for gas with 14, 130m.
The External Coating Inspection

The surveys using the methods already described, have proved to be very efficient in pinpointing the external coating failures and a lot of repairs have been carried out in points where the coating was severely degraded or did not exist any more. Up to May 2006, a total of 7,626km of the pipeline network, or 79% of total network had been inspected and a total of 3,499km were rehabilitated.
Pressure Test
In the PID standard the pressure test is either mandatory or recommended, based on the following cases: Mandatory Cases: New pipelines; After pipeline repair; Pipelines that need to operate under pressure higher than that allowed by the last valid hydrotest; Pipelines in sensitive areas. Recommended Cases: Pipelines that remain out of use for more
Conclusion
Transpetro is fully committed to the improvement of the integrity of its pipeline network. It does this through a sound pipeline integrity program which aims to achieve higher safety levels and more economical operations. The total investment of more than US$600 million covering a broad range of projects as described herein, confirms this commitment.
Geotechnical or Soil/Pipeline Interaction

The PID created the requirement to develop a geographic plan produced from aerial photography that allows the identification as well the classification and sizing on a three level scale (severe, medium and moderate), of all geological problems along the pipeline. This plan is called a themat-
Sponsored by TGS
Progress in the development of a predictive model for finding locations of significant HighpH Stress Corrosion Cracking in gas pipelines.
Transportadora de Gas del Sur S.A. is the leading gas transportation company in Argentina. Not only does TGS operate the longest and oldest pipeline system in Latin America, (7,972 Km of pipeline, 579.090 HP compression power, 74 MMm3/d of contracted capacity), it also renders integral processing services (1 million tons/year of Ethane, LPG and gasoline), treatment (12 million m3/ d) and compression (36,800 HP) of natural gas in gas fields. These services comprise construction, operation, maintenance and financial structuring. In the past, the Company overcame the challenge of achieving international standards in controlling external pipeline corrosion. Today, consistent with its policy of safety, accident prevention and its constant pursuit of quality, TGS has set up within its Pipeline Integrity Team a group of specialists and experts devoted to the research and development of a predictive model for finding cracks produced by high-pH stress corrosion cracking (SCC) in pipelines, thus preventing service interruptions arising from this phenomenon. of cracking has been a priority for TGS since its beginnings. Currently, the Company is working on two technical fronts to detect and prevent SCC effects. On the one hand, we are running in-line inspection tools (TFI & EMAT), to this date with uncertain results, and on the other hand, TGS is developing a susceptibility model. To such purposes, the team of specialists in charge of the task has developed its own soil model. titatively, the physical and chemical agents involved in this process. This fact, along with the low resistance of the soils where SCC has been found, and the proximity to rectifier facilities, has allowed TGS to present new and unknown variables to be considered in the search for significant SCC. With the implementation of a reliable susceptibility model we will be able to predict, with a high degree of certainty, the sites where significant high pH SCC is likely to be found without the need to interrupt the service for its study. It will also allow us to repair the cracks before a devastating rupture occurs. Leading the way in the investigation of this phenomenon, TGS keeps investing, developing and researching together with its team of specialists the best methodologies to mitigate and prevent SCC, thus successfully rendering excellence and quality in its service.
Observable results
The thorough research carried out by TGS' team of specialists is based on geo-morphological surveys of each area, the interpretation of high resolution satellite images, and field works which consist of observation pits, which allow the physical and morphological characterization of the soil and the extraction of samples for subsequent laboratory chemical analysis. Based on field research and by means of laboratory tests we were able to obtain artificial cracking similar to the one found in our system, thus being able to assess, qualitatively and quan-
www.tgs.com.ar
Causes and effects

SCC can be observed in pipes as a cracking in the external surfaces of pipelines (generally, lengthwise) generated by the combined action of corrosion and tension attributed to: pressure variations, high temperatures, pipeline coating conditions, soil components and cathodic protection potentials. The search for efficient methodologies and practices to detect this kind
View of cracks produced by stress corrosion cracking through pipeline wall thickness.
CTDUT
Raimar Van den Bylaardt CTDUT
The Pipeline Technology Center CTDUT is a laboratory equipped with field facilities for testing/certifying products, full scale simulations and the research and development of new technologies in pipeline activities. CTDUT is also designed to offer specialized pipeline training. CTDUT contains a pull test unit for Pig testing, an Integrity Laboratory for burst tests, a Gas Flow Loop, and a separate liquid loop for tests under real operating conditions.
In the search to develop leading edge technology for pipeline transport, CTDUT is emphasized as the fundamental link in the implantation of a Brazilian network of competence in pipelines, bringing together pipeline operators, companies, universities, research centers, civil society and government agencies. The structure built to comprise the technological center is open to all those companies and institutions that wish to strengthen the development of this project, thus enabling the multiplication of activities planned for the business and academic sectors. Nowadays, CTDUT has 19 associates: Azevedo & Travassos, Chemtech, GDK, IMC Saste, Intec do Brasil Ltda., Intech Engenharia, Pipeway, TDW, TSA Tubos Soldados Atlntico, TWI, Universidade Federal Fluminense (UFF), Conduto, Brazilian Petroleum & Gas Institute (IBP), Petrobras, PUC-Rio, Transpetro, IEC and Aselco.
CTDUT is a Technology Center created by Transpetro, Petrobras and PUC-Rio (The Catholic University) with support from the Federal Government, resources from the Oil and Gas Sectorial Fund (CTPETRO), and linked to the Ministry of Science and Technology through FINEP. It is a non-profit association open to all companies working in pipeline operation, construction, engineering, R&D, training, environment, services, and also government sectors and regulating agencies.
CTDUT
CTDUT headquarters is located in the city of Duque de Caxias, state of Rio de Janeiro, close to a Terminal from Transpetro that supplies the center facilities with oil, diesel and natural gas. The use of the pull test unit began in 1999 to verify the capability of detection, the precision of sizing and the absence of false calls. Since then, several tests of pig performance have been done with the goal of testing new technologies, tools for applications, innovative prototypes and adaptations for special case inspections. This pull test unit consists of several pipeline segments installed in a metallic structure containing shelves and an electrically powered winch that moves a wire inside all of the section of the shelves. applied in pipelines in operation. In these cases it is named internal coating in-situ. This kind of application is more complicated due to the difficulty of surface preparation and the application of the coating itself, that is commonly applied by using pigs. In Brazil, the first insitu coating application was done in 2002[1]. The average coating thickness is about 300 m. As with any pioneering work, many tests were performed to assure the quality of this new technology. Part of those tests were performed in CTDUT pull test unit to check if the MFL tool would damage the coating after a certain amount of runs and verify the influence of the coating in detecting and sizing external defects. To realize this test a 28m length specimen of pipeline segment was built and assembled into the shelves of the pull test unit. In this segment flanged spools were introduced which had the same coating as the pipeline. After the specimen was assembled, an internal inspection was realised by a MFL. From results of the test, it was concluded that when the in-situ coating was applied, the MFL tool does not damage the coating and nor is its accuracy affected by the coating. Submarine pipelines are quite often more difficult to inspect than on-shore pipelines. The access difficulties and the inadequate design for inspection with pig are the most common reason for naming these pipelines as unpiggable. Other factors also contribute for the difficulty of inspection of those submarine pipeline specially the large thickness and relatively small diameters commonly these pipelines have nominal diameters under 20 inches. To make inspection feasible of a 12 inch nominal diameter, 3/4 inch thick submarine pipeline, a specimen was assembled in the CTDUT pull test unit in order to evaluate the magnetization capability of a MFL pig. Several internal and external defects were introduced into the specimen. Some internal defects had their geometry aligned with the longitudinal direction of the pipe to simulate the typical morphology of internal corrosion defects. The tool applied in this experiment was a magnetic pig. This pig was specially designed to maximize the
Some Tests Realized in CTDUT

The internal coating of pipeline has become more important in internal corrosion prevention. More frequently pipelines are built and assembled with internal coating for reducing friction and assure a better quality of the product. Apart from application coating before pipeline assembly, sometimes the coating is
14 diameter loop - 120 meters in length.
12 diameter - 2.4km in length with integral supply tanks, pumps, automation and state-of-the-art controls.

magnetism to preserve the method sensitivity even in those adverse conditions of large thickness and small diameter. In the first trial the pig did not present sufficient magnetism, that led to a non-detection of some defects. In the second version the magnetism reached values as specified and all defects were detect. These projects will be used for research, test and training, with a participation of research centers and universities of Brazil, as well as with the operators, service companies and equipment manufacturers. The following needs had been identified to develop these projects: Research and development of new equipment, tools, inspection systems and pipeline protection. Flow tests for simulation software approval. Tests and certification of equipment and control system, protection, corrosion control, inspection and maintenance of pipeline. Certification of process and procedures of operation, inspection and maintenance. Training and qualification of operators and technicians.
References
(1) Lachtermacher, M., Souza Filho, B, Andrade, L.; Emprego de revestimento para proteo interna em dutos; 6 Conferncia sobre Tecnologia de Equipamentos 2002; IBP; Salvador-BA, Brasil. (2) Franzoi, A. Et All; Inspeo de Oleodutos com Paredes Espessas com Ferramenta MFL A experincia da Bacia de Campos; Rio Pipeline Conference 2005; IBP; Rio de Janeiro RJ, Brasil. For more information, contact the Pipeline Technology Center CTDUT www.ctdut.org.br.
Some Projects in Development

Nowadays, CTDUT is working on the construction of 3 loops: 14 diameter and 100m in length for liquid transport; 12 diameter and 2,4km in length for liquid transport; 16 diameter and 2,4km in length for gas transport.
Social and Environmental Responsibility

Pipeline right-of-way and family based agro-business
Ana Paula Grether de Mello Carvalho
In 2003, Petrobras joined one of the most important corporate social responsibility projects in the world the UN Global Compact. Since then Petrobras has definitively adopted social and environmental responsibility concerns as part of its core values. Respecting human and labor rights, protecting the environment and fighting corruption are all major challenges that face Society. Petrobras is a company that believes that its busi-
ness performance should include economic, social and environmental responsibility. The Agro-ecological Family Farming Project along Pipelines Right-ofWay is a joint Petrobras Transporte and Instituto Terra de Preservao Ambiental (NGO) and Onda Verde (NGO). Launched in December 2005, it has created vegetable gardens, an agro-industry and an Online Learning Centre in the
low income neighborhoods of Nova Iguau and Duque de Caxias, in the state of Rio de Janeiro, Brazil. The focus regions of the project are the low income communities of Gerard Danom and Jardim Geneciano in Nova Iguau Municipality, close to the borders of Tingua Nature Reserve, and the low income community of Amapa in Duque de Caxias Municipality. All of them are crossed by the stretch of pipeline (ROW).

Since most of the dwellers of those communities live below the poverty line, it is crucial to implement social projects that promote job and income generation and encourage social organization. Moreover, Petrobras Transporte considers agriculture a form of fostering closer relations with the population in the neighborhoods on the edge of its underground pipelines, and of protecting its equipment and the population against possible accidents caused by third party actions. The Agro-ecological Family Farming Project along Pipelines Right-of-Way consists of a fivemodule agro ecological production unit, covering a production area of 96,000 m (100 vegetable gardens of 960 m), directly serving 100 farming households. The project not only contributes toward maintaining the pipelines, in compliance with the safety and environmental standards adopted by the company but also assists lowincome households by providing technical support and financing to find better jobs and increase levels income generation. The novel aspects of the project are the promotion of social inclusion and guaranteeing economic, environmental and social sustainability through two main points. First, adopting participative/ongoing diagnosis and planning methodologies, creating an evaluating and planning culture by the methodology of Participative Rural Diagnosis (PRD). Second, the objective of placing the organic productions in the market, throughout local and regional production chains and arrangements, provides ways to add value to the local farm production, including the families in certified production chains. The methodology of Participative Rural Diagnosis (PRD) aims to perform critical and integrated analysis of the rural reality involving the population and the project technical assistants. The PRD is not a conventional diagnostic process in which specialists collect information from the farmers then later unilaterally plan the activities of the project. The purpose of PRD is to encourage dialogue between farmers and specialists in order to set up an environment of discussion and analysis of community problems, so that it is possible for different groups to express different opinions on such problems. By using visual diagrams for collecting information, such as a spoken map, flowchart, Venn diagrams and other tools, the local population and the project technical assistants are able to build diagrams and discuss results. The outcome of the work is a collective understanding of how reality is to be transformed. Such methodology engages the participants deeply in the project and at the same time empowers the local population so that they become aware of this social space and how to transform it. Supporting The Agro-ecological Family Farming Project along Pipelines Right-of-Way, Petrobras shows its committed to extending the quality of its positive performance to social action at the communities where it operates. This is the way that Petrobras System proposes to fight against poverty in Brazil: Development with Citizenship.
Feeler Snake Pig: a Simple Way to Detect and Size Internal Corrosion
Claudio Camerini & Miguel Freitas
Submarine Pipeline Inspection

Submarine pipelines are traditionally inspected with the same technologies used for onshore pipelines. A good example of this is an inspection using instrumented pigs, which is usually based on the same parameters, procedures, and tools used in onshore inspections. In those circumstances, some problems, of course, are expected to happen. Onshore pipelines are usually easy to access, and that enables excavating for field verifications and correlations, thus allowing inspection quality measurement. The same is not true for submarine pipelines, in which a correlation of instrumented pig indicated results implies very high costs or, in some cases, is not technologically possible. During the 1980s and 1990s, onshore pipelines received strong investments in Brazil in order to be able to receive instrumented pig inspections, such as: removing small radius bends; installing launchers and receivers; unifying diameters; and removing obstacles. Some submarine pipelines received the same treatment, but those adaptations were not extended to the whole network, once the investments required were, at least, of a higher level. Its very common, therefore, to find submarine pipelines with various diameters and small radius bends, among other obstacles that prevent the use of conventional instrumented pigs. Other equally relevant factors make the inspection difficult, like submarine pipeline wall thickness, which limits significantly the use of magnetic instrumented pigs MFL magnetic flux leakage. As oil production heads for deeper and deeper waters, pipelines become thicker for structural reasons, and that implies loss of MFL pig measurement capacity. Those pigs present reduced sensitivity as from 15 mm-thick wall with a practical limit of 20 mm. The problem becomes more serious in diameters smaller than 14inch diameter pipelines, which present large thickness and small internal volume, making magnetization very difficult, as the space available to place magnetizers is not much. With current technology, there are not enough compact and high-power magnetizers to be used on large thicknesses in such small spaces. Another characteristic of submarine pipelines inspections is that almost always those pipelines are accessed from outside, with visual inspection using ROVs Remotely Operated Vehicles. Those vehicles are already periodically used to inspect Petrobras submarine pipelines, to identify external damages, measure cathodic protection electrochemical potential, identify spans, etc. That external visual access is, compared to onshore pipelines, the greatest differential regarding submarine pipelines inspection. Another aspect that favors submarine pipelines is that the main cause of deterioration is internal corrosion, which occurs in the presence of produced water. External corrosion is easily prevented with cathodic protection, while damage caused by collisions or anchor action are, mostly, identified through ROV visual inspection. It is considered, therefore, that the main objective of inspecting oil and gas production submarine pipelines is to detect and quantify internal corrosion and, in a lesser degree, external defects related to diverse actions. An alternative technology available in the market to inspect pipelines subject to internal corrosion is the use of pigs with ultrasound technology. Depending on its mechanical design, the ultrasonic pig may
Figure 1 - Feeler Pig measuring method. Corrosion effects (pits) are measured according to angle variation of sticks.

eter variation, in addition to short and long pipelines with a wide range of flow speed. In July, 2006, an inspection was performed using a feeler snake pig, which is a fully innovative design using the above mentioned method. Figure 3 shows the new concept of instrumented pig, in which sensors (sticks) are mounted on a flexible base. That tool enabled a multi-size inspection, with small radius bends, a kind of inspection that tools commercially available cannot provide. As a result, 7.6 kilometers of a submarine pipeline were recovered. For consolidating the feeler pig technology and the feeler snake pig concept, Petrobras is changing its submarine pipeline inspection systematic, prioritizing that technology for internal corrosion control. The use of other pigs, like MFL and ultra-sound, will still occur whenever there is a suspicion of external corrosion. With the new system, Petrobras intends to inspect the vast majority of its submarine pipelines, practically eliminating the expression non-piggable line from its offshore production fields. Therefore, Petrobras pioneers the inspection of production pipelines that were usually excluded of routine pigging inspections.
Figure 2 - (a) Feeler pig for 22, with 250 sensors (sticks); b) Feeler pig for 16, with 180 sensors (sticks).
tolerate variations in diameter, and does not present inconveniences for measuring large thicknesses. A severe limitation to that method is the need for a homogeneous liquid, with good acoustic properties, to serve as coupler. That limitation makes it more difficult to inspect gas pipelines, requiring introduction of a diesel batch, but with strong operational impact. Also, the fluid is not homogeneous in production pipelines with live oil (oil + gas + water), making ultrasonic inspection practically impossible. In this context, Petrobras, together with PUC-RIO, developed a submarine pipelines inspection method to detect and size up loss of wall thickness associated to internal corrosion. A special pig was designed to bear large variations in diameter, have no practical limit of thickness to be inspected, and be able to navigate through curves and geometric accessories with small bend radii. The tool was named a Feeler Pig, as it consists of several feeler-type sensors that measure internal corrosion, as illustrated in Figure 1. At first, the special pig was developed for small diameter production pipelines, however, because of its potential shown in field tests, a first prototype was constructed for large diameter pipelines, in this case, 22 inches. That prototype carried out an
inspection of a submarine pipeline in Campos Basin, with excellent results, thus confirming the tools potential in the field. Figure 2 shows the pig assembled and ready to use. Results delivered by the pigs 250 sensors (sticks) were compared with a previous inspection performed with a commercial ultrasound pig. The new tool delivered results that were identical to those of the ultrasonic pig, confirming, therefore, under real conditions, the technical viability of the new internal corrosion detection and quantification method. Based on the aforementioned results, several inspections using that system are being scheduled for 2006 to 2008, and include oil and gas pipelines with or without diam-
Figure 3 - Feeler Snake Pig a new concept of instrumented pig, where sensors are mounted on a flexible base to allow inspection of usually nonpiggable pipelines. (a) batteries and electronics modules; (b) 12 sensor modules, totaling 144 sensors distributed across pipelines perimeter; (c) general view of equipment during pre-launch check.
Pipeline and Shipping Technology Supports Petrobras

Csar Jos Moraes Del Vecchio
R&D activities in Petrobras on these subjects are coordinated by means of a Technological Program PROTRAN, with specific projects led by specialty groups from Petrobras R&D CENPES as well as by participating in joint industry programs and projects. PROTRAN, dedicated to pipeline technology since 1997, in its early stages has put substantial effort in qualifying and helping to assimilate the most up-to-date solutions available for operational challenges. Recent work on pipelines has been part of the international industry effort to improve safety, minimize risk and reduce capital and operational costs. The present portfolio of PROTRAN includes projects in eight subjects: Corrosion Management; Leak Detection Systems; Pipeline Rehabilitation; In Line Inspection (ILI); Pipeline Operation and Automation; Risk management; Pipeline Design, materials and construction technology;
Ship design, construction and integrity management. Most of the projects are developed in house, with part of the scope contracted to Brazilian science and technology institutions, however some are contracted abroad. We consider part of this portfolio a group of eighteen projects we support as members of Pipeline Research Council International (PRCI). Also part of the portfolio are eight projects targeted at increasing the capabilities of Brazilian Universities and Institutes to support a set of 26 ships that will be built for Petrobras Transporte SA, run directly by Rio de Janeiro Federal University, So Paulo State University and The So Paulo Institute of Technology. The following paragraphs discuss some highlights of projects that have just finished or are under way.
than in onshore pipelines, made it difficult to detect and quantify the internal corrosion of the lines. Petrobras R&D changed this scenario with the development of an in-line inspection tool. The innovation, known as the 'Pig Espinho' is able to identify and measure loss of pipeline wall thickness caused by internal corrosion. It is based on a series of very sensitive feeler rod and miniature electronics. It can handle large diameter variations and has multiple uses as it can inspect thicknesses of any size and can negotiate tight bends. It is also able to by-pass geometrical accessories with narrow bend radius and can tolerate high temperature and high-pressure environments. Figure 1 shows sensing elements on a 22 diameter ILI tool used in an offshore pipeline. A recent run has
Multi-size ILI Tool

The existing equipment, known as Conventional Instrumented Pigs, used in inspections of onshore pipelines was not ideally suited for use in sub sea oil and gas production pipelines. Frequent diameter variations, large wall thicknesses, sharp-angled bends, and the most varied geometrical configurations, which are far more prevalent in sub sea pipelines
Figure 1 - Crown of sensing elements in 22 Pig Espinho.

made it possible to inspect an offshore line which has a flexible riser.
Corrosion Management in Wet Gas Pipelines

Typical strategies to mitigate CO2 corrosion to acceptable levels are: continuous corrosion inhibition, batch corrosion inhibition, gas dehydration, pH control and corrosion-resistant alloys (CRA). In the Cango-Pero field, offshore Esprito Santo-Brazil, there is no facility available for liquid/gas separation and treatment on the topside of the jacket. All production (gas, condensate and produced water) from Pero is transported for processing to one separation and one TEG dehydration facility onshore. On the platform, there is a chemical injection system, in order to prevent hydrate formation and inhibit corrosion, including a dedicated pig launcher for batch treatment. No sand production is expected and the CO2 content is 1.25% and 3.06% for Pero and Cango respectively. After a number of simulations and studies Petrobras chose a carbon steel pipeline with a corrosion allowance of 6 mm and corrosion inhibitor treatment as a suitable materials/corrosion control approach. One of the concerns for the 18 main pipeline is under-deposit corrosion and proper inhibitor transportation. Under-deposit wall loss can be very fast even in generally low-corrosion medium. Frequent launching of scraper pigs would therefore be needed to ensure cleanout of any solids in the pipeline and cup-discs to enhance inhibitor transportation. Since the predominant flow pattern is stratified wavy, CO2 corrosion rates will be different at the bottom of the line (BOL) and at the top of the line (TOL) and there are also implications for corrosion inhibition application.
Figure 2 - Artistic view of the pipes and pig launcher for the batch treatment.
Under these conditions, a continuously applied corrosion inhibitor is not expected to wet the top of the line. As the 18 gas export pipeline is heavily oversized, it creates a risk of severe corrosion damage due to potentially ineffective corrosion control by inhibitor continuous injection. Combined batch inhibition is required for protecting the top. To enhance the batch treatment, the design team developed an innovative method for this operation. For that reason, the platform design considered two pig launchers. One vertical pig launcher will be used to run up to seven pigs for the normal operation with an initial frequency expected every two days. The second pig launcher is horizontal and will be used for the batch operations. As the platform is small and crowded, a creative design configuration was devised to allow for the installation of the two pig launchers. Figures 2 and 3 show the batch system. The pipeline has a dynamic side stream corrosion monitoring system and has just been commissioned.
Figure 3 - Artistic view of the Pero platform.
Pipeline and Shipping Technology to support Petrobras Group

The Influence of Topographic Scale in Mass Wasting Susceptibility Modeling
The purpose of mass wasting susceptibility assessment using a Geographic Information System is to assign, in a regional scale, places were these events are more probable to take place. The main purpose of mass wasting susceptibility maps is to provide information about the probability of mass wasting occurring. The way in which the digital elevation model (DEM) is obtained, by interpolation or by mesh, has an enormous influence in determining the main topographic parameters of this surface, like the contributing area, the flow direction, the slope and the hill slope curvature. A variety of studies on mass wasting susceptibility modeling applied to a pipeline in steep hill slopes of the Serra do Mar, close to the city of Rio de Janeiro, where mainly creeping process are occurring, were performed. In these numerical experiments both deterministic (e.g., SHALSTAB Shallow Landslide Stability Model and TRIGRS Transient Rainfall Infiltration Grid-Based Regional Slope Stability Analysis) and empirical models (e.g., SMORPH Slope Morphology Model) were used, as well as a modification of this model in order to detect areas affected by creep processes. Besides, a model based on soil and rock properties mapped in the field (IPT Model) was also tested. In order to characterize the influence of topographic scale in our ability to predict landslide susceptibility, the simulations were carried out in scales 1:1.000, 1:10.000 and 1:50.000. The Serra do Mar is a mountain range nearby the Southeastern Brazilian coast in the states of Rio de Janeiro, So Paulo, Esprito Santo and Paran with hill top elevations varying from 300 to 2.000 meters. The study area is located in a steep hill slope near the coast in the state of Rio de Janeiro, just West of Rio de Janeiro city. An important pipeline goes through these W-E oriented hill slopes, which are mainly composed by Precambrian metamorphic rocks as gneisses and migmatites, locally known as Rio Negro Complex.
Figure 4 - The creeping area (red lines) with inclinometers assigned by their labels and showing that the process is occurring in high contributing areas.
The Brazilian Gas Transportation System

Marcelo Renno, Director Petrobras Transporte
Introduction
Natural gas is the worlds fastestgrowing primary energy source, being more environmentally attractive as it burns efficiently; it is expected to be the fuel of choice in many regions. As a result of this, the natural gas share of the total world energy matrix will grow from 24 percent in 2003 to 26 percent in 2030 measured in BTUs. In Brazil alone, the consumption of natural gas will be growing at 12% to 15% per year on average, led mainly by vehicular natural gas (VNG) and by the industrial market. Petrobras, the state controlled Brazilian energy company, is the principal player in the Brazilian natural gas industry. Its goal for 2011 is to market an average of 120 million cubic meters of natural gas per day, well above the current total of nearly 46 million cubic meters per day. To meet this impressive growth in natural gas demand, the gas transportation network will need to be expanded significantly, with a view to connecting the different regions of the country.
Gas Pipeline Network

Natural Gas in Brazil Natural gas usage in Brazil started in the 1960s with the development and production of reserves in Bahia state, in the Northeast of the country. For this reason the first gas pipeline, called GASEB, was constructed linking the State of Bahia to the State of Sergipe, as shown in fig.1. Natural gas exploration continued at a low level in the 1970s until the worldwide oil crises motivated efforts in exploration and production. Due to these efforts, results started to be achieved with the discovery of reserves in the Esprito Santo and Rio de Janeiro states (Campos Basin). This fact, associated with industrys fuel demand, led to the construction of gas pipelines throughout those states. At that time, the gas pipelines called GASVIT, GASVOL and GASPAL were concluded (see description in table 1). The latter links the states of Rio de Janeiro and So Paulo. The 1980s saw the start of natural gas transportation and distribution to the northeast area of the country. The gas pipeline called Nordesto entered into operation supplying Paraba and Pernambuco states with gas produced in the State of Rio Grande do Norte. In the 1990s production from the Merluza Field began in the Santos Basin, supplying natural gas to the Refineries of Presidente Bernardes and Capuava (GASAN) and connecting the State of So Paulo to the natural gas supply system. To complete the gas pipeline network in the southeast area of Brazil, the gas pipeline called GASBEL entered in operation in 1996, allowing the natural gas produced in the Campos Basin to be supplied to the State of Minas Gerais. Towards the end of the 1990s, two new gas pipelines of great importance were constructed: GASFOR
The Brazilian Gas Transportation System

and GASALP, expanding the natural gas supply network in the Northeast region of Brazil. At that time the domestic market was supplied only by the domestic gas production. This situation changed in 2000, with the conclusion of the Bolivia-Brazil gas pipeline (GASBOL), which started the process of natural gas importation from other countries. The Bolivia-Brazil Pipeline (GASBOL) The Bolivia-Brazil pipeline was the outcome of many years of negotiation between the Governments of the two countries but it was not until the 1990s that it became part of the Brazilian strategy for securing energy supplies. The resulting agreements and contracts allowed the construc3 tion of a 30 million m /d gas pipeline connecting Bolivian reserves to the Southernmost part of Brazil and also to the pipeline network supplied by the Campos Basin. The pipeline takes gas from the Rio Grande area in Bolivia and ultimately supplies it 3,150 km away in Canoas (Rio Grande do Sul state in Brazil). The pipeline crosses the Brazilian states of Mato Grosso do Sul, So Paulo, Paran, Santa Catarina and Rio Grande do Sul; and connects with the existing gas transportation facilities in Sao Paulo state. The pipeline has a diameter ranging from 32 to 16 inches. It is designed to reach a gas outflow of 30 million cubic meters per day when operating at full capacity. The GASBOL implementation used the most advanced technology in terms of construction techniques, remote operational systems, line pipe material specification and inspection and testing methodology. It is important to highlight that the Engineering Department of Petrobras was in charge of the design and project implementation. After the construction, TBG (Transportadora Brasileira Gasoduto Bolvia-Brasil S.A.) in Brazil where Petrobras is the main partner and GTB (Gas TransBoliviano) in Bolivia became the owners and operators of the pipeline in their respective countries. The Bolivia-Brazil pipeline includes twelve compression stations, seven operational measurement stations for pig launcher/receiver facilities located along the pipeline and thirty eight pressure measurement and reduction stations to supply the various gas distributors. The Gas Pipeline Network in Operation At present, there are three independent gas systems in operation that are not interconnected, due the continental dimensions of Brazil: (i) the Southern-Southeastern System (SSE), (ii) the Northeastern System (NE) and (iii) the Esprito Santo state system, which has not yet had its pipelines connected to the S-SE system despite being located geographically in the Southeast Region; Apart from the Brazilian part of the Bolivia-Brazil Pipeline, the table below shows the current network in Brazil. The existing natural gas pipeline network is fully operated by Transpetro (Petrobras Transporte S.A) and TBG, which operates the Brazilian part of GASBOL. Transpetro is the Petrobras System logistics company, and is responsible for operating areas such as the transportation and storage of crude oil, oil products, biofuels, petrochemicals and gas through pipelines, terminals and ships owned by the company and third parties. Transpetros gas pipeline network transportation capacity is increased by compression stations located at strategic points. There are ten compression stations in operation, distributed in the Northeast and Southeast regions of Brazil. All of Transpetros operations are controlled from the National Op-
Table 1 - Brazil Gas Pipelines.

erational Control Center (NOCC) that monitors Transpetros network of oil and gas pipelines with the exception of supply lines belonging to third parties and ship loading and unloading lines at port terminals. The NOCCs basic concept was developed entirely by Transpetro engineers. The NOCC is located in the Transpetro headquarters in downtown Rio de Janeiro. The system enables operators to open and close the valves controlling the flow of gas, adjust the quality and content of the gas, and conduct sales at the other end, all at the click of a button. In addition to optimizing the planning and transportation of products, real-time monitoring of the network provides greater operational safety. Petrobras will speed up its development projects in the Santos (So Paulo state), Esprito Santo and Campos (Rio de Janeiro state) Basins, significantly increasing the domestic natural gas supply. To transport this additional input volume, the Petrobras Business Plan foresees the enhancement of the Southeastern regions gas pipeline network. Expansion work will also be undertaken in the Rio-Belo Horizonte Gas Pipeline (Gasbel), in the Southern section of the Bolivia-Brazil Gas Pipeline (Gasbol) to supply the Southern region with the gas produced in the Southeast and in the Northeastern network. With the implantation of the Southeast Network and Gasene projects in the next 3 years, Petrobras will complete the basic Brazilian national gas pipeline grid. The figure below shows the current and future gas pipeline network in Brazil.
Conclusion
The increasing share of natural gas in the Brazilian energy matrix is the result of higher investments throughout the supply chain. This has enabled the development of the natural gas industry in Brazil. As a result, Petrobras registered an increase of 13% in the demand of natural gas in the first quarter of 2006 in relation to the same period of the previous year, which confirms the forecasts of the Companys Strategic Plan that forecasts an annual growth rate of 17.7% up to 2011. The future commitment and challenge is to continue transporting the entire volume of natural gas with high levels of performance, assuring optimum gas network reliability, environmental responsibility and high safety standards.
Gas Pipeline Network Expansion

The Petrobras Business Plan has allocated US$ 6.5 billion for gas pipeline network expansion up to 2011, thereby increasing the existing 5,570 km of gas pipelines by a further 4,160 km. The projects include construction of the Urucu-Coari-Manaus gas pipeline in the Amazon region and also new gas pipelines in the Southeast and Northeast regions of Brazil. Meanwhile, the Gasene which will interconnect Southeastern and Northeastern Brazil will be concluded by 2008. This gas pipeline will be formed by sections ranging from Cabinas (Rio de Janeiro state) to Vitria (Esprito Santo state), from Vitria to Cacimbas (Esprito Santo state), and from Cacimbas to Catu (Bahia state), totalling 1,215 kilometers. This will expand Brazils gas pipeline network to nearly 10,000 km, a measure considered a key element of the companys strategic plan to more than double natural gas consumption by 2011.
Figure 1 - Brazil Gas Pipelines.
Marcelo Jos Barbosa Teixeira1, Claudio Roberto Mansur Barros1, Mnica de Castro Genaio1, Carlos Terencio Pires Bomfimsilva2, Vivianne Cardoso Pessoa Guedes2, Janaina de Figueiredo Loureiro2 1 Petrobras S.A.; 2 Intec Engineering
The Golfinho Field is located in the Esprito Santo Basin, offshore Brazil, and will be producing 100,000bpd of light oil through an FPSO moored at a 1,350m water depth by 2006. The produced gas will be exported onshore to the Gas Processing Unit, in Cacimbas, via a 12-inch steel pipeline, which is fitted with a PLET at the deep end to allow for subsea connection to the flexible riser. The geophysical and oceanographic survey started with the first option proposed by the engineers. The immediate onboard evaluation of the data showed that the continental slope of the area had an extremely complex near-surface geology characterized by the presence of canyons and ravines associated with gradients up to 60 at the shelf break. Due to this reason and the fact that the Golfinho field was located in a region with few previous studies, it was then decided to conduct a semi-regional scale highresolution geophysical, geological and geotechnical survey to aid the identification of natural and man-made obstacles that could represent any risk to the structural integrity of the pipeline as well gain an understanding of the geological and oceanographic factors responsible for the features observed on the seafloor. The entire survey was conducted between April and October 2004, with
over 470km of area limited by the 60m and 1,380m isobaths (outer continental shelf and medium slope) and consisted of a single-beam bathymetry for seafloor morphology investigation, side scan sonar with 100% percent coverage for superficial sediment distribution evaluation and a 3.5kHz sub-bottom profiler for the investigation of subsurface structures. A geological and geotechnical sampling campaign using a 6 meter long piston-corer was also conducted with coring locations selection based on the geophysical records. Dating of selected samples was done using biostratigraphic methods. The integrated interpretation of all geophysical and geological data allowed the identification of the most critical factors such as high slopes and areas of the seafloor dominated by erosional processes, which should be avoided for the design route. Moreover, the understanding of the geological history of the area led to a qualitative slope stability evaluation as a function of the geological environment. The selected route corridor was determined considering all aspects that could represent risk to the pipeline integrity. This approach proved to be very useful by restricting more detailed and time-consuming geotechnical investigation to the final corridor considerably reducing the final budget of the survey.
Acquisition of oceanographic data included deployment of two mooring lines along the pipeline route, one in 300m and the other in 1,300m depth, during a one-year period. The mooring lines were equipped with an acoustic current profiler for the top 100m and current meters with CTDs distributed along the line. The lowest current meter was deployed at a 5m distance from the seabed in order to quantify bottom currents, which are crucial for pipeline design. Data acquisition for the shore approach area consisted of simultaneous measurement of directional waves and current profiles, which was carried out using an acoustic current profiler with wave processing capacity deployed at 20m depth. Each month beach profiles and sediment grain distribution were also quantified, in order to provide data for numerical simulation of beach seabed profile evolution and support pipeline burial specifications.
Structural Design
The most important activities within the structural design were material and corrosion assessment, wall thickness design and pipelaying feasibility analysis. The entire pipeline was primarily specified as seamless pipe with the minimum yield stress of 415MPa. The material and corrosion assess-

ment was then performed to check the suitability of adopting C-Mn steel pipe to convey the gas containing 0.56% of CO2, and operating with the maximum pressure and temperature of 230kgf/cm2 and 50C respectively at the PLET in a potentially wet environment. The corrosion rates were then estimated following the De Waard and Milliams prediction model along the entire pipeline, considering the CO2 partial pressure, the operating temperature profile, the operating pressure profile, and the pH values. In addition, the effect of corrosion inhibitors with efficiency of 95% was also considered as a reduction factor for the corrosion rates. As a result, the total corrosion allowance of 3.0mm was determined for water depths varying from 850m to 1,200m approximately and 1.6mm for shallower water depths. In order to determine the required wall thickness for the pipeline, three failure modes were considered for the entire route: burst pressure; buckling due to combined bending and hydrostatic pressure; and buckle propagation, which were assessed based on the methodology proposed by DNV OS F-101. These failure modes, when checked over the pipeline phases, i.e. pipelaying, hydrotesting and operation, resulted in the following load cases: Pressure containment operation Pressure containment hydrotesting. during during Buckle propagation during installation. Buckle propagation depressurization. during the design: select a thicker wall capable of resisting buckle propagation; or weld buckle arrestor collars at a selected spacing along the pipeline, which are designed to prevent the propagating buckle from crossing over, limiting the pipeline damage extension to the design spacing between successive buckle arrestors. A thicker wall that resists buckle propagation has been extensively designed when the reel-lay method is applied, since it would be unpractical spooling the buckle arrestor collars onto the reel. In the Golfinho export pipeline, an additional requirement has been established, where the pipeline should resist the buckle propagation at the end of its lifetime, i.e. after the corrosion allowance has been consumed, so the pipeline damage due to a potential local buckling would not propagate in case the pipeline is depressurized in the operational phase. The required wall thickness to resist propagation criteria is presented in Figure 1. The step at 850m for the depressurization condition is related to the change in corrosion allowance. The 20.6mm (0.812-inch) has been proposed for water depth deeper than 100m water depth, since it is located in a rough seabed region and the increase in wall thickness will improve the free span capability.
For the pipeline installed by the reellay method, no concrete coating is allowed and the selected wall thickness of the pipe also needs to provide sufficient weight to ensure on-bottom stability, mainly in shallow waters. In addition, the reel-lay method requires the pipe to be designed with sufficient wall thickness for spooling the pipeline onto the reel without achieving the critical strain. In this case, the minimum nominal pipe wall to comply with the critical strain criterion is 15.9mm (0.625-inch). The wall thickness design for deepwater depths is mainly governed by external hydrostatic pressure, and the most critical phase for the pipeline is during pipelaying, where the pipe may be subjected to a high bending loading due to a loss of surface positioning of the pipelaying vessel. In case the pipe is designed with a thin wall, sufficient to resist the combined hydrostatic pressure and bending, and an unexpected buckle is formed, it will propagate until a lower hydrostatic pressure is reached, and this may lead to damage to a large section of the pipeline. In order to avoid this situation, two strategies are typically adopted in
Local buckling due to combined bending and external pressure during installation Local buckling due to combined bending and external pressure during depressurization.
Figure 1 Wall thickness design to resist propagation buckle.
It was noted that using an 80-degree pipelaying ramp at 1,200m would require a 1,472kN top tension to lay the 12-inch pipeline designed with 25.4mm (1.000-inch) wall. In order to minimize the top tension during pipelaying in deepwater depths, a conceptual design for internal buckle arrestors was investigated. For this case, a 22.2mm (0.875-inch) pipe would be selected for deepwater, being sufficient to resist buckle propagation during installation. This pipe requires a 12-inch pipe with a thicker wall to be butt welded to the pipeline at a given spacing to function as a buckle arrestor. The 31.8mm (1.250-inch) wall thickness was selected based on the DNV OS-F101 recommendations. The internal buckle arrestors could be welded within the stalks in preparation for the spooling to avoid reducing pipelaying speed. Most of the pipeline route is, however, located in shallow water depths, 50km approximately, where the wall thickness is governed by on-bottom stability as shown in Figure 2. The assessment of the installation feasibility was performed using the commercial Finite Element Software Offpipe, which is dedicated for pipelaying analysis. The analysis was performed by checking the stress levels along the pipe related to the pipelaying geometry for the range of the project water depths. It is worth emphasizing the following aspects related to the selection of pipelaying ramp angle: Bottom Tension is relevant for the number and size of free spans, and high ramp angles will result in lower bottom tension, consequently, allowing for free span optimization. A higher ramp angle also requires lower top tension, which is essenFigure 2 - Required Wall Thickness for On-Bottom Stability.
tial in deepwater depths to keep the required top tension within the vessel capacity. Higher ramp angles, however, are limited by the stress levels observed at the sagbend region, mainly in shallow water depths.
Route Optimization
The pipeline route can now be optimized, i.e. re-routed to minimize the number and size of free spans, by assessing alternative routes in the anticipated rough regions, considering the seabed features observed from the produced geophysical maps. First, the allowable free span needs to be determined, so the number of potential free spans may be estimated when assessing the alternative routes. In the proposed optimized route, the number of free spans higher than 1.0m was reduced to 19, and none is anticipated to be higher than 3m.
Geophysical survey has shown that the critical area along the pipeline route was in the shelf break and in deepwater, specifically in water depths ranging from 100 to 350m. The route was optimized and the number and size of free spans was drastically reduced. Due to the presence of canyons, ravines and scarps, the pipelaying in this area should proceed under the lowest values of tension as possible, in order to minimize the residual tension along the pipe, maintaining the free spans under the established limits of pipe stress and spans lengths. The allowable free spans were determined based on available local information, which was not in a proper format for vortex induced vibration analysis. The allowable limits were then determined resulting in preliminary short free spans which should be revised once the oceanographic campaign provides more realistic information for the fatigue analysis.
Final Remarks
Little environmental information was available for pipeline design, since the Esprito Santo Basin is a new area of development in deepwater offshore Brazil. A geophysical and oceanographic campaign was then put forward to provide rationale information for the pipeline design work.
Acknowledgements
The authors would like to thank Petrobras pipeline design and marine installation group for their supportive work mainly during the geophysical and oceanographic survey, and for their comments and suggestions kindly presented during the preparation of this paper.
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Marcelino Guedes Director, Petrobras Transporte

a free standing hybrid riser for deepwater

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Paulo de Tarso Arruda Correia Petrobras Transporte

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Paulo Roberto Costa Director Petrobras Bunkering

Sergio Machado President, Petrobras Transporte

Renato Duque Director Petrobras Services

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Liquid Pipelines and Terminals

Liquid Pipelines and Terminals Guedes

Graphic shows Petrobras Emergency Bases

CREs Transpetro Management 34 CDAs Petrobras Management 9 Advanced CDA Bases 6

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Graphic shows Schematic of Pipelines

New riser development a free standing hybrid riser for deepwater

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Fig. 1 shows Configuration A.

Fig. 2 presents Configuration B.

Riser Development Roveri

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Projects and Construction of New Oil and Gas Pipelines in Brazil

Souza & Passos

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Transpetro Pipeline Integrity Program

The Emergency Phase

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Transpetro's Pipeline Network Regional NNE SE SPCO SOUTH TOTAL 42 60 61 20 183

Quantity Nr. Pipelines Nr. Row 15 14 27 9 65

Lenth KM 2596,83 2763,54 3260,00 1029,90 9650,28

The Adjustment to Petrobras Pipeline Standard

Internal Corrosion (IC)

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The CPS Supervisory System

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The External Coating Inspection

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Some Tests Realized in CTDUT

14 diameter loop - 120 meters in length.

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Some Projects in Development

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Pipeline and Shipping Technology Supports Petrobras

Multi-size ILI Tool